Lockout Tagout (LOTO) 101: Steps for Safer Workplaces

Workplace safety is non-negotiable in any industrial facility, especially when hazardous energy is involved. Millions of workers perform high-risk servicing and maintenance on industrial machinery daily. These tasks, while routine, expose workers to severe hazards.

Lockout/Tagout (LOTO) procedures are essential for ensuring safety during equipment servicing or maintenance. Each year, thousands of preventable injuries occur due to the uncontrolled release of hazardous energy. According to the Occupational Safety and Health Administration (OSHA), proper LOTO implementation can prevent over 50,000 injuries annually. But what exactly is LOTO, and how do you implement it correctly? Let’s explore the key steps and precautions involved.

Read More: Lockout/Tagout Training, Requirements and Benefits

What Does LOTO stand for?

LOTO stands for Lockout and Tagout, a critical safety procedure that controls hazardous energy in the workplace. The term encompasses two complementary safety methods: lockout involves using physical locks to prevent equipment from being energized, while tagout uses warning tags to indicate that equipment should not be operated.

Here’s an overview of the difference between Lockout and Tagout.

What Are the Steps in LOTO Procedures You Must Follow?

Proper lockout/tagout procedures improve workplace safety by preventing unexpected startups or energy releases. Your LOTO process should follow these comprehensive steps to ensure complete protection. Each step builds on the previous one to create a foolproof safety system.

Step 1: Notify Employees

Before starting any LOTO procedure, notify all affected employees about the planned maintenance or repairs. Tell them when the work will happen, which equipment will be locked/tagged out, how long it will last, and what alternatives are available during downtime.

Step 2: Know Your Procedures and Spot the Dangers

Identify your documented LOTO procedures and prepare them for implementation. Make sure you have all the necessary information about the equipment, including instructions for shutting down, locking, tagging, and restarting. Procedures should identify energy types, hazards, control methods, and magnitude levels.

Step 3: Get Ready Before You Shut Down

Ensure all involved employees are trained in LOTO procedures and fully understand the specific equipment and methods being used. Good preparation helps prevent injuries and ensures everyone knows their role in the process.

Step 4: Isolate Equipment

Isolate the equipment from all energy sources, electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other. Use circuit breakers, valves, or blocking devices to eliminate energy. A stop button is not enough; you must fully disconnect and neutralize energy sources.

Step 5: Use Locks and Tags

Apply lockout/tagout devices to all identified energy sources. Locks prevent reactivation, while tags provide visible warnings about ongoing work. Each tag should include the date, time, reason for lockout, and contact information of the person who applied it.

Step 6: Check for Stored Energy

Inspect for any residual or stored energy and safely release it. This includes draining pressure, venting gases, discharging capacitors, and ensuring moving parts like flywheels or springs are stabilized.

Step 7: Verify Isolation

Confirm that all energy sources have been properly isolated. Attempt to operate the machine using normal controls (a “try-out” test) while observing monitors, gauges, or other indicators. Check that no residual energy remains.

Step 8: Turn Off the Controls

Once isolation is verified, turn off all controls or set them to a neutral position. Confirm locks and tags are still in place and visible to nearby personnel. At this point, it is safe to begin repair or maintenance work.

Step 9: Return to Service

After maintenance is complete, remove all tools and unnecessary items from the area. Ensure employees are at a safe distance. Maintenance personnel should reassemble safety components like guards and access panels. Then, remove LOTO devices, reset controls to “on,” and return the machine to normal operation.

Read More: How OSHA10 Training Increases Workplace Safety in Construction

What are the Types of Hazardous Energy Controlled by LOTO?

When you ask, “What does LOTO stand for?” you're really asking about protection from more than just electrical energy. Every time you service or maintain equipment, you're exposed to multiple hazardous sources, including,

• Electrical Energy: High-voltage machinery, wiring, circuits, and capacitors can cause shock, burns, or death. This includes stored electrical energy that remains even after the power is disconnected.

• Mechanical Energy: Moving parts like rotating shafts, conveyor belts, and springs under tension, as well as machinery components, can crush, cut, or trap workers.

• Hydraulic Energy: Pressurized fluid systems (often exceeding 3,000 PSI) can inject fluids into the skin or cause explosive failures of system components.

• Pneumatic Energy: Compressed air systems can cause serious injuries through high-pressure release or unexpected movement of cylinders and components.

• Thermal Energy: Heat sources such as furnaces, hot pipes, steam lines, and heated surfaces can cause severe burns and may retain dangerous temperatures long after shutdown.

• Chemical Energy: Reactive chemicals may generate heat, pressure, or toxic gases, or create explosive conditions when mixed or exposed to certain environments.

Common LOTO Mistakes that Lead to OSHA Violations

Workplace LOTO violations often stem from an inadequate understanding of LOTO and poor implementation. In fact, according to OSHA's penalty structure, businesses that willfully or repeatedly violate their regulations can be fined up to $16,550 per violation. Let’s take a look at some of them to avoid the pitfalls that lead to lockout tagout injuries and OSHA citations. 

Inadequate Written Procedures

Many organizations fail to develop specific procedures for each piece of equipment. Generic procedures don't address the unique hazards of individual machines, leading to incomplete energy isolation and potential lockout tagout injuries.

Insufficient Employee Training

Employees often receive minimal training on lockout tagout procedures. Without a comprehensive understanding of the lockout tagout OSHA standard, workers may skip critical steps or fail to recognize all energy sources.

Failure to Use Proper Devices

Using the wrong lockout devices or not using any at all is a major violation. Each energy-isolating device must be secured using hardware specifically designed for that application.

Poor Communication and Coordination

Lack of communication between shifts or departments creates dangerous situations. When employees don't understand what does LOTO stand for or fail to follow established procedures, accidents become inevitable.

Read More: What are OSHA Toolbox Talks?

A Safe Workplace is a Productive Workplace

As a responsible employer, you must prepare employees by teaching them about what does LOTO stand for for to create a safer workplace. Lockout and tagout procedures save lives, prevent injuries, and protect your organization from costly violations. Make sure to follow established OSHA lockout tagout rules, provide comprehensive training, and stay current with best practices. 

Enhance your emergency response capabilities by enrolling in our online LOTO course today. When workplace emergencies occur, proper awareness and training can make all the difference while waiting for professional medical help to arrive.

Reference:

• 6 Steps of Lockout Tagout (LOTO) Safety | Vector Solutions

• 7 Steps To Reach LOTO Safety

• What Does LOTO Stand For and Why Lockout/Tagout Is Important

• Control of Hazardous Energy (Lockout/Tagout) - Overview | Occupational Safety and Health Administration